Planishing machine

ABSTRACT

A planishing machine and process for reshaping parts wherein an anvil roll supports a brake shoe plate with a surface of the desired shape of plate. The anvil roll has a radial slot to receive the brake shoe web. Paired form rolls for ironing the plate against the anvil roll under force are swung on paired arms to advance and retract each form roll relative to the anvil roll. The form rolls are triangulated relative to each other and to the anvil roll and to avoid interference in the confined workpiece space and to provide separate control and power means to advance and retract each form roll. Coordinated drives turn the anvil roll and the form rolls at about the same peripheral surface speed.

[451 July 18, 1972 [54] PLANISHING MACHINE [72] Inventor:

m e M d mm :L t mm Walter L. Jewett, Royal Oak, Mich.

[73] Assignee: Allied Welder Corporation, Detroit, Mich.

[22] Filed: Dec. 10, 1970 57] ABSTRACT A planishing machine and processfor reshaping parts wherein [21] App! 96,698 an anvil roll supports abrake shoe plate with a surface of the desired shape of plate. The anvilroll has a radial slot to receive the brake shoe web. Paired form rollsfor ironing the plate against the anvil roll under force are swung onpaired 12/101 1 1 1, 120, 124 82, arms to advance and retract each formroll relative to the anvil 72/80, 73; 113/116 0; 29/905 roll. The formrolls are triangulated relative to each other and to the anvil roll andto avoid interference in the confined s1 InLCl.............. 5sFieldofSearch.....................

workpiece space and to provide separate control and power ReferencesCited means to advance and retract each form roll. Coordinated UNITEDSTATES PATENTS drives turn the anvil roll and the form rolls at aboutthe same m u .W F g n i w r D 8 d. m e m e l W C m 6 m S d r e h P n eD. H l 1/ n y .m mvw n 0 a m S PATENTED JUL 1 81972 SHEET 1 [IF 4 F'lG.l

INVENTOR 110417514 4. JEWETT' ATTORNEY PATENTED JUL 1 8 I972 SHEEI 2 OF4 INVENTOR YZXM ATTORNEY PATENTED JUL 1 8 I972 SHEET 3 OF 4 \NVENTOR#491727? Z. awn-"r7 F' IG.3

ATTORNEY PATENTEB JUL 1 8 I972 SHEET L 0F 4 KM KN HUWHHUHHUHM n ATTORNEYPLANISHING MACHINE This invention relates to a planishing machine whichcorrects the contour inaccuracies of a part resulting from the imposedheat and force applied to the part in welding the part from componentpieces.

A vehicle brake shoe is such a part and includes an arcuate plate and anarcuate web welded together. The heat and force of the welding operationdeforms the plate and web and produces high and low spots at the weldsrequiring correction to within acceptable manufacturing tolerances.

With the foregoing in view, it is a primary object of the invention toprovide a planishing machine for correcting welded brake shoes, forexample, which is simple in design and construction, inexpensive tomanufacture, and easy, reliable, efficient, and inexpensive to use.

An object of the invention is to provide a planishing machine which iseasily modified to operate on different size brake shoes as by changingthe anvil roll and/or the form rolls.

An object of the invention is to provide a machine which is capable ofplanishing several sizes of brake shoes on a single anvil roll such asfor example, shoes of 14 to 18 inch diameter on an anvil roll of 14 inchdiameter.

An object of the invention is to provide a machine which will planishbrake shoes of various widths on a single anvil roll within thediametrical range of the anvil roll.

An object of the invention is to provide a machine which eliminates theneed for a die for each size brake shoe and a huge press to supply theneeded force, such as a 400 ton press.

An object of the invention is to provide an anvil roll of desired sizeand shape and two form rolls forceably engagable with the anvil roll toplanish the brake shoe therebetween.

An object of the invention is to triangulate the anvil and form rollsand their operating mechanism so that both form rolls can be brought tobear on the brake shoe in the confined work space so that both formrolls engage the brake shoe at the same time over a long traveldistance.

An object of the invention is to drive the anvil and form rolls atsubstantially the same peripheral surface speed to minimize stressesimposed on the welds of the brake shoe.

An object of the invention is to provide a relatively small planishingmachine, as compared to a 400 ton press, which is capable of exerting aline force on the workpiece up to 800 tons per square inch to shape theworkpiece by applying up to 25 tons of force from each of the cylindersto force the form rolls against the workpiece with line contacttherebetween.

An object of the invention is to roll-form or planish the workpieces toeliminate the operation of scoring or crosshatching the surface of theworkpiece to break skin resistance and reduce spring back as is theusual practice in reshaping a workpiece in a press.

An object of the invention is to provide a machine which applies arolling force on a line to the workpiece to overcome skin resistance andspring back. v

An object of the invention is to provide a machine which can beintegrated easily with other machines which cannot be done with a largepress requiring special below-floor foundations, and which is easilyautomatically loaded, unloaded, and/or included in an automated transfermachine.

An object of the invention is to provide a machine which can onlyreceive a single workpiece at each workpiece position on the anvil rollso that double loading or hitting is eliminated.

An object of the invention is to provide an anvil roll which is capableof receiving a plurality of workpieces so that they may be loaded,rolled, and unloaded at various circumferential positions on the anvilroll in a continuous operation which may be easily automated.

An object of the invention is to provide a process for straighteningparts which alters the character of the workpiece by changing it from amalformed part to a correctly formed part, by superposing the part on ananvil roll base, engaging the part with form rolls under pressure, androtating the anvil roll and the form rolls to pass the part therebetweento subject the part to line-force radially between the anvil and formrolls with the line force moving the material and overcoming skin andsub-strata resistance to eliminate spring-back in any substantial degreeto thereby reshape the part.

These and other objects of the invention will become apparent byreference to the following description of a planishing machine embodyingthe invention taken in connection with the accompanying drawings inwhich:

FIG. 1 is an end elevational view of the planishing machine of theinvention, partly in cross-section, with parts broken away and in dottedlines to show interior construction.

FIG. 2 is a cross-sectional view of the machine shown in FIG. 1, takenon the line 2-2, thereof showing a brake shoe in cross section betweenthe anvil roll and a form roll.

Fig. 3 is a cross-sectional view of the machine shown in Fig. 2 taken onthe line 3-3 thereof showing the anvil roll drive means.

Fig. 4 is a cross-sectional view of the machine shown in FIG. 1 taken onthe line 4-4 thereof showing the form roll support and drive means.

FIG. 5 is a side elevational view of a brake shoe, showing the welds indotted lines.

FIG. 6 is a cross-sectional view of the brake shoe shown in FIG. 5 takenon the line 6-6 thereof.

FIG. 7 is a top plan view of the brake shoe shown in FIG. 5 as seen inthe direction of the arrow 7; and

FIG. 8 is a partial end elevational view of the connections between theswing arms and the rams taken in the direction of the arrow 8 of FIG. 1.

Referring now to the drawings wherein like numerals refer to like andcorresponding parts throughout the several views, the planishing machineand brake shoe shown therein to illustrate the invention comprises aframe 20. An anvil roll 21 is rotatably supported on the frame 20 andhas a surface 22 and a radial slot 23, FIGS. 1 and 2. The brake shoe 24,FIGS. 5-7, has an arcuate plate 25, an arcuate web 26, aninter-connecting welds 27, and a key-tab 28 on web 26 lying in anaperture of the plate 25. The tab 28 and plate 25 are also weldedtogether. The anvil roll slot 23 receives the brake shoe web 26 and theanvil roll surface 22 lies behind the brake shoe plate 25, FIG. 2. Aspace 29 exists between the web 26 and the bottom of the slot 23. A pairof form rolls 30 and 31 engage the brake shoe plate 25. Paired swingarms 32 and 33 rotatably support the form roll 31. Paired swing arms 34and 35 rotatably support the form roll 30. A ram 40 and a power cylinder41 are connected to the swing arms 34 and 35 to advance and retract theform roll 30. A ram 42 and power cylinder 43 are connected to swing arms32 and 33 to advance and retract the form roll 31. Drive means, laterdescribed, turn the anvil roll 21 and form rolls 30 and 31 atsubstantially the same peripheral surface speed to planish the brakeshoe plate 25, web 26, and connecting welds by rolling the brake shoe 24between the rolls. As the web 26 is free to move into the space 29, thereforming of the plate 25 corrects the web 26 but without encounteringresistance from the web 26.

More particularly, an axle 50 supports the anvil roll 21. The anvil roll21 is keyed or splined on the axle 50. Sleeves 52 and 53 and bearings 54and 55 rotatably support the axle 50. The axle 50 and sleeve 52 arekeyed or splined to each other for rotational drive from the sleeve 52to the axle 50. The axle 50 is thus mounted for angular movement withthe sleeves 52 and 53 and for axial movement relative to the sleeves 52and 53.

A worm gear 56 is keyed on the sleeve 52. An outboard bearing 57supports the sleeve 52 outwardly of the worm gear 56, FIG. 2. A worm 58drives the wonn gear 56. A shaft 59 drives the worm 58, which, in turn,is driven by a pulley 60, belt 61, pulley 62 and motor 63. It isapparent that by energizing the motor 63, that the anvil roll 21 isdriven with reduced speed and increased force.

A power cylinder 64 is fixed on the frame 20 axially of the axle 50. Apiston rod 65 extends from the cylinder 64 and is connected to the axle50. A free wheeling connector 66 allows the axle 50 to move angularlywithout rotating the piston rod 65.

To replace the anvil roll 21, the power cylinder 64 is actuated towithdraw the piston rod 65 which pulls the axle 50 out of the anvil roll21. With the axle 50 pulled from the anvil roll 21, it may be replacedwith a like or different roll 21 and remounted by operating the cylinder64 to extend the piston rod 65 which moves the axle 50 axially throughthe anvil roll 21 and into the sleeve 53.

Referring now to the form roll supports and drives, uprights 70 and 71are part of the frame 20. A pivot pin 72 is supported between theuprights 70 and 71, FIG. 4. The swing arms 32 and 33 are bearinged onthe pivot pin 72 so that the arms may swing thereon. A sprocket gear 73is sleeved on the pin 72. A spur gear 74 is sleeved on the pin 72. Thesprocket gear 73 and spur gear 74 are keyed together by a stud 75. Apinion gear 76 engages the spur gear 74. A stub shaft 77 is rotatablybearinged on the frame 20. The stub shaft 77 is keyed to the pinion gear76. A sprocket gear 78 is keyed to the stub shaft 77. The swing arms 32and 33 may be viewed as triangular and that the pin 72 pivotally mountsthe arms 32 and 33 at the pivot corner.

At a second corner of the swing arms 32 and 33, an axle 80 is pivotallybearinged between the swing arms 32 and 33 and supports the form roll 31to which it is keyed. An outboard sprocket gear 81 is also keyed on theaxle 80. An endless chain 82 connects drive from the sprocket gear 73 tothe sprocket gear 81, axle 80 and form roll 31.

A cross-bar 83 spans the swing arms 32 and 33 at their third corner,FIGS. 1 and 8. Clevises 84 and 85 are welded on the cross-bar 83. Aconnecting rod 86 lies between the clevises 84 and 85. A wrist pin 87pivotally mounts the connecting rod 86 relative to the clevises 84 and85. A socket 88 is formed in the top end of the connecting rod 86. Theram 42 of the power cylinder 43 fits in the socket 88. Outward movementof the ram 42 pivots the swing arms 32 and 33 on the pivot pin 72 tomove the form roll 31 on the swing arms 32 and 33 toward the anvil roll21. A drag link 89 bolted between the ram 42 and connecting rod 86 movesthe form roll 31 away from the anvil roll 21 with inward movement of theram 42. The power cylinder 43 has trunnions 96 which are bearinged intrunnion sockets 97 on the frame 20.

The swing arms 34 and 35, form roll 30, cylinder 41, and ram 40 aresimilarly equipped and integrated as described in connection with theswing arms 32 and 33. An idler sprocket gear 93 is mounted on the frame20.

A fluid motor 90 is mounted on the frame 20. A pinion gear 83 is drivenby the fluid motor 90. A large spur gear 83 A is driven by the piniongear 83. A prime sprocket gear 91 is driven by the spur gear 83 A via ashaft 83 B. An endless prime chain 92 leads over and around primesprocket gear 91 and the sprocket gear 78 at arms 32 and 33, and thesprocket gear 78 at arms 34-35. The prime chain 92 leads under the idlersprocket gear 93.

The fluid motor 90 thus drives the prime chain 92 which in turn drivesthe sprocket gears 78. The sprocket gears 78 drive the stub shafts 77and pinions 76. The pinions 76 drive the spur gears 74 and attachedsprocket gears 73. The sprocket gears 73 drive the chains 82. The chains82 drive the sprocket gear 89 on the form roll axle 80 at each form roll30 and 31.

The fluid motor 90 speed and reduction to the form rolls 30 and 31 andtheir circumference is coordinated with the motor 63 speed and reductionto the anvil roll 21 and its circumference to turn the rolls 21, 30 and31 at substantially the same peripheral surface speed to avoid skiddingand imposing cross-strain on the welds of the brake shoe 24. The fluidmotor 90 has been found advantageous as it provides a resilient drivewhich allows the form rolls to increase or decrease in speed at theanvil roll without undue load in either drive train.

The forces exerted on the brake shoe 24 may be varied by adjusting thefluid pressure supply to the power cylinders 41 and 43 and coordinatedto the size of the form rolls 30 and 31 for exerting the desired rollingline force on the brake shoe 24. The speed of the rolls may also becoordinated to the exerted forces imposed on the brake shoe.

The brake shoe 24 is placed on the anvil roll 21 with the web 26 in theslot 23. Spring detents, adjustable studs, magnets, etc. may be used tohold the brake shoe 24 on the anvil roll 21 as it approaches, passes,and leaves the form rolls 30 and 31.

The form rolls 30 and 31 may operate in continuous forced engagement ormay be alternately advanced and retracted by suitable servo-mechanismsas suits the needs and desires of the particular operation.

In operation, the planishing machine is hand loaded or preferablyautomatically loaded and unloaded. In a brake shoe operation, themachine may be located after the welding machine and ahead ofdown-stream operations. Thus the shoes are straightened immediately andmay be used immediately.

In processing parts in the planishing machine, one form roll 30 and 31makes first contact under low applied force with the leading edge of theworkpiece as it is advanced angularly by the anvil roll 21. Uponengagement with the form roll the applied force is increased. The secondform roll 30 or 31 then makes contact under low applied force with theleading edge of the workpiece; the force applied to both form rolls 30and 31 then is increased to the desired maximum. Thus the workpiece isplanished from end to end with the desired maximum force with the formrolls applying the force along line of contact of the periphery of eachform roll. While this contact is described as line contact" it will beunderstood that the maximum line of force will be at the apex of theform roll periphery relative to the workpiece with areas of increasingand decreasing applied force on either side thereof. The engagementforces are increased and decreased by controlling the pressures suppliedto the cylinders 41 and 43 by conventional means and the indexingcontrolled by means such as cams coordinated to the length of theworkpiece or stops turning with the anvil roll. The speed of rotation isalso coordinated to the applied force and the size of the workpiece.

The planishing machine is thus capable of planishing large brake shoesfor the biggest trucks and small brake shoes for the littlest cars asthe machine is variable as needed to apply the desired force at thedesired rotational speed as best suits the workpiece being planished.

While a brake shoe has been described as a suitable workpiece, it willbe understood that this is exemplar-y and that other parts may be shapedby the machine as the scope of the invention is limited only by theappended claims.

I claim:

1. A planishing machine for correcting contour inaccuracies in the shapeof a welded workpiece without damaging the weld connections, comprising,

a frame,

an axle rotatably mounted on said frame,

an anvil roll fixed on said axle having a peripheral surfacecomplimentary to the desired shape of the workpiece;

said anvil roll having means for receiving, positioning, and

holding a workpiece thereon,

first and second pairs of trunion sockets mounted on said frametriangulating with said anvil roll axle and with each other,

first and second power cylinders having trunions mounted in said firstand second pairs of trunion sockets,

a ram extending from each said cylinder toward said anvil roll,

pivot pins mounted on said frame outwardly of said anvil roll andoutwardly relative to each said ram; a pair of swing arms havingtriangulated action points positioned between each said ram and saidanvil roll and pivotally swingable at one action point on said pivotpins;

a cross-bar on each said pair of swing arms at a second action pointhaving a connecting rod connected to one said ram,

a shaft between each said pair of swing arms at a third action point, aform roll on each said shaft for bearing against said anvil roll;

each said ram, connecting rod, cross-bar, and form roll lyingsubstantially on an axis with said pivot pin off-set relative thereto;

said power cylinders, when retracting said rams, connecting rods, andcross-bars, swinging said arms on said pins to move said form rolls awayfrom said anvil roll;

said power cylinders, when advancing said rams, connecting rods, andcross-bars, swinging said arms on said pins to move said form rollstoward said anvil roll and into forced engagement with the workpiece,and

means rotationally driving said anvil roll and said form rolls atsubstantially the same peripheral surface speed to pass the workpiecebetween said rolls in forced engagement to planish the workpiece to thedesired shape.

2. in a machine as set forth in claim 1,

said anvil roll having a relieved portion in the location of the weldsof the workpiece to diminish the strain imposed on the welds.

3. in a machine as set forth in claim 1, said means rotationally drivingsaid anvil roll comprising a worm gear on said axle, a worm driving saidworm gear, and power means for driving said worm.

4. In a machine as set forth in claim 1, said means rotationally drivingsaid form rolls comprising,

a sprocket gear keyed to each said form roll, a sprocket gear free onsaid pin, a spur gear free on said pin, a stud connecting said sprocketgear on said pin with said spur gear on said pin, and a final drivechain transferring drive between said sprocket gear on said pin and saidsprocket gear keyed to said form roll,

a stub shaft rotatably bearinged on said frame,

a pinion gear keyed on said stub shaft engaging said spur gear, and asecond sprocket gear keyed on said stub shaft,

an idler sprocket ear on one said paired arms, a fluid motor on saidframe having a drive shaft, a prime drive sprocket gear on said gearmotor drive shaft, and

a prime drive chain leading over said prime drive sprocket gear, oversaid second sprocket gears on said stub shafts, and under said idlersprocket gear.

5. In a machine as set forth in claim 1, the workpiece being a 5brake-shoe having an arcuate plate and an arcuate web,

said anvil roll relieved portion being a radial slot for receiving theweb of a brake shoe, and said anvil roll having a surface complimentaryto the desired shape of the arcuate plate. 6. In a machine as set forthin claim 1, said means for rotationally driving said anvil rollcomprising,

an axle in said anvil roll; a key lying between said axle and said anvilroll preventing relative angular motion to provide rotational drive tosaid anvil roll and permitting relal tive axial movement to provide forwithdrawing said axle from said anvil roll; said axle having oppositeend, a first sleeve housing said axle at one end thereof, on one side ofsaid anvil roll, a second sleeve housing said axle at the other endthereof on the other side of said anvil roll,

bearings rotatably mounting said sleeves, a worm gear mounted on onesaid sleeve to import rotational drive to aid sleeve, said sleevecarrying said worm wheel being keyed to said axle to import rotationaldrive to said axle;

said key connection between said sleeve and said axle allowing relativeaxial movement of said axle; a power cylinder mounted on said frame, onthe axis of said axle, and a piston rod leading from said cylinder andconnecting to said axle axially thereof;

said power cylinder and piston rod being capable of withdrawing saidaxle from said anvil roll when mounted to dismount said anvil roll andof advancing said axle through said anvil roll when dismounted to mountsaid anvil roll.

l i i it

1. A planishing machine for correcting contour inaccuracies in the shapeof a welded workpiece without damaging the weld connections, comprising,a frame, an axle rotatably mounted on said frame, an anvil roll fixed onsaid axle having a peripheral surface complimentary to the desired shapeof the workpiece; said anvil roll having means for receiving,positioning, and holding a workpiece thereon, first and second pairs oftrunion sockets mounted on said frame triangulating with said anvil rollaxle and with each other, first and second power cylinders havingtrunions mounted in said first and second pairs of trunion sockets, aram extending from each said cylinder toward said anvil roll, pivot pinsmounted on said frame outwardly of said anvil roll and outwardlyrelative to each said ram; a pair of swing arms having triangulatedaction points positioned between each said ram and said anvil roll andpivotally swingable at one action point on said pivot pins; a cross-baron each said pair of swing arms at a second action point having aconnecting rod connected to one said ram, a shaft between each said pairof swing arms at a third action point, a form roll on each said shaftfor bearing against said anvil roll; each said ram, connecting rod,cross-bar, and form roll lying substantially on an axis with said pivotpin off-set relative thereto; said power cylinders, when retracting saidrams, connecting rods, and cross-bars, swinging said arms on said pinsto move said form rolls away from said anvil roll; said power cylinders,when advancing said rams, connecting rods, and cross-bars, swinging saidarms on said pins to move said form rolls toward said anvil roll andinto forced engagement with the workpiece, and means rotationallydriving said anvil roll and said form rolls at substantially the sameperipheral surface speed to pass the workpiece between said rolls inforced engagement to planish the workpiece to the desired shape.
 2. In amachine as set forth in claim 1, said anvil roll having a relievedportion in the location of the welds of the workpiece to diminish thestrain imposed on the welds.
 3. In a machine as set forth in claim 1,said means rotationally driving said anvil roll comprising a worm gearon said axle, a worm driving said worm gear, and power means for drivingsaid worm.
 4. In a machine as set forth in claim 1, said meansrotationally driving said form rolls comprising, a sprocket gear keyedto each said form roll, a sprocket gear free on said pin, a spur gearfree on said pin, a stud connecting said sprocket gear on said pin withsaid spur gear on said pin, and a final drive chain transferring drivebetween said sprocket gear on said pin and said sprocket gear keyed tosaid form roll, a stub shaft rotatably bearinged on said frame, a piniongear keyed on said stub shaft engaging said spur gear, and a secondsprocket gear keyed on said stub shaft, an idler sprocket ear on onesaid paired arms, a fluid motor on said frame having a drive shaft, aprime drive sprocket gear on said gear motor drive shaft, and a primedrive chain leading over said prime drive sprocket gear, over saidsecond sprocket gears on said stub shafts, and under said idler sprocketgear.
 5. In a machine as set forth in claim 1, the workpiece being abrake-shoe having an arcuate plate and an arcuate web, said anvil rollrelieved portion being a radial slot for receiving the web of a brakeshoe, and said anvil roll having a surface complimentary to the desiredshape of the arcuate plate.
 6. In a machine as set Forth in claim 1,said means for rotationally driving said anvil roll comprising, an axlein said anvil roll; a key lying between said axle and said anvil rollpreventing relative angular motion to provide rotational drive to saidanvil roll and permitting relative axial movement to provide forwithdrawing said axle from said anvil roll; said axle having oppositeend, a first sleeve housing said axle at one end thereof, on one side ofsaid anvil roll, a second sleeve housing said axle at the other endthereof on the other side of said anvil roll, bearings rotatablymounting said sleeves, a worm gear mounted on one said sleeve to importrotational drive to aid sleeve, said sleeve carrying said worm wheelbeing keyed to said axle to import rotational drive to said axle; saidkey connection between said sleeve and said axle allowing relative axialmovement of said axle; a power cylinder mounted on said frame, on theaxis of said axle, and a piston rod leading from said cylinder andconnecting to said axle axially thereof; said power cylinder and pistonrod being capable of withdrawing said axle from said anvil roll whenmounted to dismount said anvil roll and of advancing said axle throughsaid anvil roll when dismounted to mount said anvil roll.